Building construction



s sheets-sheet 1 J. c. MORRELL BUILDING coNgTRUcTIoN Filed Nov. 7, 19:58

July 2, 1940.

\ July 2, 1940. J. c. MoRRELL BUILDING' CNSTRUCTIN 3 sheets-sheet 2Filed Nov. 7, 1938 www@ 8 5 Z. i

July 2, 1940. J. c. MORRELL BUILDING CONSTRUCTION 3 Sheets-Sheet 3 FiledNaw 7,. 1958 Patented July`2, 1940 4UNITED STATES;

PATENT 4OFFICE. u l y 2,200,233 surnoms, coNs'raUo'rroN Jacque C.Morrell, Oak Park, Ill.

l Application November "l, 1938, Serial No. 239,281

5 claims. l(ci. 'zz-1 6) This invention is a continuation in part of myapplication No. 118,966, filed January 4, 1937, and particularly refersto an improved method and means of wall construction, especially adaptedThese slabs are placed between spaced stud meml bers in the outer wallsof the structure and are permanently aillxed to the adjacent studs andthus retained in place in the wall by various alternative butnon-equivalent means which do not impair the good insulatingcharacteristics of-the slabs, or of the wall as a whole. Preferably then slabs are so placed in relation to the studs. as to provide a layer orthickness of insulationbetween the outer faces or flanges ofthe studsand outer faces of the wall.

One specific embodiment of thev invention,

wherein the structural framework of the outer walls of a buildingincludes spaced wood or metal studs such as, for example, H-columns,I-beams,

or channels havlngflanges substantially parallel.`

to opposite faces of the wall, the slabs of wall or U insulatingmaterials or pairs of slabs of insulating material or in general wall'material facing one another, are attached to the studs by membersembedded in the slabs and are attached to the studs by suitablehanger-clips or brackets or 8l' by other means as hereinafter described.In a specific embodiment the attaching means comprise various deviceswhich are transverse to the thickness of the slabs or in generalperpendicular to the faces, and which permit the slabs to be 40 placediiush with the face of the stud or lie flat against it.

General forms as well as several specific forms of the above mentionedembedded members may be employed withinthe scope of the invention. Oneof said general formscomprises a suitable bar. rod, tube, hook and eye,snap, clips, and simi- 'lar devices or other suitable device which maybe embedded in the slabs at spaced intervals at the time the slab isfabricated, or at any time prior` to its placement in thewall, theembedded members being attached to the studs as the slab i is placed inpositin. In some forms the attaching members may ynot necessarily beembedded in la the slab although in this case'prov'ision is preferablymade forallowing the slab to be placed flush with the stud. r

With the types of embedded members above mentioned they may eitherextend between and protrude from opposite vertical edges of the slab.

` or may extend only part way intothe slab from,

its vertical edges or they may be embedded and/or attached to the facenext to the stud. In one modification the slabs may also be attacheddirectly to the studs by nails or screws, the heads of 1 which arepreferably counter-sunk or combination methods of attachment selectedfrom those described may be employed. It is to be understood that thevarious methods described are .non-equivalent although departures andvaria- 15 tions within the scope of the invention are to be includedtherein.

As one of the features of the'present invention,

the slabs or pairs of slabs attached adjacent studs are placed withtheir inner faces or, surfaces flatly against the faces or flanges ofthe studs to' which they are attached and the slabs are rela tively:thin and are preferably not corner notched as are those in the parentapplication.

As a feature of the present invention I may employ slabs or wall boardmade of brous or com-V position insulation material upon which issuperimposed a relatively. thin layer of separately formed plasticmaterial, preferably made laminated fabric, e. g.,paper saturated with asyn- 30 thetic resin but which may also be in the form of a pre-formedsheet of plastic material such as from a molding mixture of a plasticand filler material or the molded plastic alone. This .may'i be ilxed.integrally "l10n the insulation board or 35 Wall slab with a suitableadhesive and serves the purpose of both interior and exterior decorationand protection. The various modifications of the y plastic layer isdescribed and claimed more completely .in an application which iscopending 'with o the present one. l

In the drawings, 1

Fig. 1 is a plan sectional view of a wall constructed in accordance withmy invention, said section being taken on the line I-i of Fig. 2. 45

' wards the top of the flange.

Fig. 13 is a face sectional view of a hanging de- A vice shown in Fig.12.

Fig. 17 is a sectionalelevational view of a buildillustrating myimproved wall structure as used for an outer building wall.

Referring in detail to the drawings, I-I in- .dicates a plurality ofI-beams which are Avertically disposed in spaced relationship to providebuilding wall studs. Each of the I-bearns I comprises a web 2 andopposite flanges 3. Of course, it is to be understood that other ironshapes may be utilized since my invention is not predicated or dependentupon the use of I-beamsfor studs. U-shaped metal members 4 are securedto the'flanges 3 of the I-beams at spaced points along the length of'theI-beams. Each of the members 4 .is provided with a back 5 and spacedanges 6. Preferably, the members 4 are constructed of metal and thebacks 5 are welded to the flanges 3 of the I-beams so as to cause theanges 8 to project outwardly from the I-beams. Preferably, the members 4are disposed in pairs of opposite flanges of the I-beam.

Each of the flanges 6 of the members 4 is provided with a taperedslot 1which opens to- .The slots 1 are adapted for the reception of the endsof rods 8 which are embedded in the thickness 0f Wall panels 9. The Wallpanels 9 may be constructed of fibrous material in general of organic ornumeral characteristics preferably having heat insulating properties.The panels 9 are preferably constructed in rectangular units and eachunit carries one or more, and preferably two or more, embedded rods 8.Corner portions of the panels 9 are recessed as indicated at I0 in Fig.4, said` recesses occurringwhere the ends of the rods 8 project from thepanel material. f

To assemble a wall II constructed in accordance with my invention, thepanels 9 are disposed in spaced relationship on each side of the I-beamsI and the ends of the rods 3 are positioned in the slots 1. It canreadily be seen that the panels '9 abut along the' line of the studs andmay be positioned one above the other between adjacent studs.

Referring in detail to Fig. 17, my invention is illustrated as employedin an usual building I2. The building I2 comprises the usual foundationI3, lower door I4,- upper floor I5, upper ceiling IB and roof I1. Aplurality of I-beam studs I are vertically positioned upon thefoundation I3. At the top of said studs an I-beam I8 extendstransversely. Upon the upper flange of the I-beam I8 another pluralityof I-beams I are vertically positioned in spaced relationship along thelength of the beam I3. A plurality of wall panels 9 are hung upon themembers 4 which are carried by the I-beams I by meanslof the embeddedrods 8. Upon the outer surface of the wall, sheathing I9 may bepositioned. Instead of the sheathing I9, said outer surface may becovered with clap boards, or other suitable covering known to the artsuch asl brick, stucco and weather protecting material generally. Theinner panels 9 may, if desired, be covered with plaster 20 or otherdecorative material,

I-beam studs which are positioned in a manner similar to the studs I.Each of the I-beams 2| comprises a web 22 and opposite flanges 23.Angular members 24 are secured to one or both anges of the I-beams 2.Iby means of bolts 25 or the like.

It is to be understood, of course that any convenient means ofattachment of the members 24 to the I-beam flanges is'contemplated. Theangular members 24 are positioned in pairs upon the flanges 23 and aredisposed in such a manner as to provide spaced spring arms 26. Wallpanels 21 are adapted to be carried by the I-beam studs 2|, each of thepanels carrying one or more embedded rods 28 which project at each oftheir ends into a recess 29, similar to recess I0 hereinbeforedescribed. The ends of the rods 28 are adapted to be inserted betweenthe adjacent spring arms 26 and said arms are suitably curved toresiliently or frictionally retain the rods 28. To provide furtherretention of adjacent panels 21 on each side of the web of the I-beam,pairs of angular members 24 are positioned adjacent each other." Ifdesired, the

wall illustrated in Figs. 5, 6, 7, instead of carri/'fy ing one set ofpanels 21, may carry spaced sets of panels similar to wall II.

- Referringparticularly to Figs. 8 to 16 inclusive; modified forms ofhanging means are illustrated.

-In view of the fact that in many instances thewall panels are of thesame construction wherever similar elements are described, the samereference numerals will be used.

Referring'particularly to Fig. 8, a vertical stud 30 ,of I-beamconstruction is adapted to carry a plurality of panels 3|. The panels 3|are provided wlth recesses 32 similar to the recesses I0 and 29hereinbefore described. One or more rods 33 may be embedded in thethickness of the panels 3| and extend 'into the recesses 32. At spacedpoints along the length of each ofl the studs 30, hook-like members 34are secured to the flanges of the studs by means of bolts 35 or othersecuring agencies.

Referring particularly to Fig. 9, the hanging members comprise angularplates 36, each ofv which has an outwardly extending flange 31. A notch38 is provided in the flange 31 for the -reception of the end of rod 33,the notch 38 resembling a bayonet slot.

Referring particularly to Fig. 10, the stud 3|!l carries a plurality ofpanels 39. In this form of my inventionthe panels are not provided withthe customary rods 3, 23 or 33, 'but are provided with downwardlyprojecting hooks 40 which are.

secured within recesses 4I `to the panels 33 by means of nails or screws42. At spaced intervals along the length of the studs 30, tubularmembers 43 are secured to the anges of said studs, the downwardlyextending hook member being adapted to engage in the tubular member 43.The tubular members 43 are preferably welded to the studs 30.. y y A`the slots. In this Vform of my invention the rods 4B do not extendthroughout the entire width o the panel.

Referring particularly to Figs. 12 and 13, an I- beam stud 3II isillustrated as carrying a plurality of panelsv 44, said panels beingprovided with recesses 45 similar to the recess described in conjunctionwith Fig. '11. Rods. extend across the recess 45 and are embedded inthepanel thickness on each-side of the recess. Said rods are adapted toengage in the hanging member 41, each of which comprises a lower hookmember 48 and an upper clamping member 49 between which the rods 4 5 arepositioned. l

Referring particularly to Fig. 14, an I-beam stud 30 `is illustrated ascarrying a panel 3l similar to the panels Q and 21. A plurality ofrecesses 32 similar to recesses I0 and- 29 are provided in the panel. Inthis form of my invention, an eyelet member 50 is carried by I-beam 35and secured thereto by bolts` 5| or otherwise. An engaging member 52having an upper hooklike element 53 and a lower clamping element 54, iscarried by the panel, the engaging member being secured tothe panel bymeans of nails or screws55. The hook-like member 53 and clamp member 54engage the encircling eyelet 53.

Referring particularly to Fig. l5, an I-beam 33 carries a forwardlyextending hook 56 which` is secured to a ilange of the I-beam by meansof bolts 51 or' the like. The I-beam is adapted to carry a panel 3lhaving a plurality of' recesses 32 similar to recesses I0 and 29. Aneyelet 58 is carried by the' panel 3| and secured thereto by means ofnails or screws 59.

Referring particularly to Fig. 16, I-beam stud 30 carries an eyelet 50which is secured to the flange of the I-beam by means' of bolts or thelike 6I. A panel 3| is carried by the I-beam, said panel being providedwith a plurality of recesses 32. `A downwardly extending hook'member 62is secured to the panel 3| by means of bolts or screws 83.

In order to make the attaching means moresecure and to `prevent movementofthe slabs cement or cementitious materials or in `general portion ofthe materialshaving 'adhesive and/or plastic properties which may setafter drying or curing, may be placed in or around the attaching meansJust prior to placing the slabs inposition.

Nailing strips may be employed wherever convenient or necessary forattaching either interior or exterior'iinishes, such as plaster or ex-lpanded metal for the interior or clapboard on the exterior. These maycomprise wood strips suitablydisposed in the slabs.

Although wood-siding is indicated at i3 in Fig. 17 the inventioncontemplates the use of any desired type'of exterior finish 'for thewall slabs, such as', for example, brick or stone veneer, stucco, metalsiding, or the like, Exterior finishes, such as plywood, or sheets ofany other desired material which .is sumciently resistant todeterioratlon from moisture and varying'weather conditions, may beapplied to the slabs after they are installed or may be furnishedintegral with the individual wall slabs, being attached, inthe lattercase, to the underlying surface of the slabs by glueing, or in any otherdesired manner.

A plaster finish 20 applied directly to the interior surface of the wallslabs, is here illustrated, although the invention contemplates the useof any other acceptedv type of interior ilnish,

Vsuch as for example, wood or` plywood panels,`

metal sheets, tiling or simulated tile, linoleum or the like which maybe integral'with the slabs as they are installed, or may be attachedthereto in any desired manner after the slabs are installed in the wall.Reinforced mesh, such as expanded metal lath, or the like, may lbeemployed with plaster or other plastic finishes on the interior surfaceof the wall. when desired, as well as with the stucco finishes, or thelike, for the exterior surface.

It will be apparent from the foregoingthat the invention `provides anumber of related but nonequivalent methods and means of attaching slabsof wall materials to spaced stud members in the wallsv ofa structure.Each of these methods and means is particularly well adaptedto use withwall slabs composed primarily of the so-called rigidtype ofheat-insulating materials such as gypsum blocks or preferably slabs of-insulation composed of brous materials, ofvegetable, animal or mineralorigin, as wellas other types of insulating slabs and blocks such as,for'example,

cast or molded materials containing ingredients of good insulatingquality or a high percentage 'of relatively small voids or pockets ofentrapped air or inert gas. 'I'he features of the invention areparticularly dsirable inconnection with the use of slabs or blocks ofinsulating materials" Molded or precast slabs of hydraulic cement, convcrete, natural or synthetic resins, ceramic materials and the like maybe attached to the framing members of any type of structure in themanner and by the means herein provided.-

As applied to buildings such as houses. oilice buildings, factories andthe like, any desired form and type of interior and exterior wallmaterials may be utilized in" conjunction with the wall slabs. Whenplaster is employed as an interior finish it is preferably applieddirectly to the in-v terior surface of the slabs although expanded metallath, wire mesh'or the like may, of course, be utilized as a base, whendesired. Stucco and kellastone or the like may be applied to theexterior surface of the slabs either without or, preferably, with asuitable reinforcing mesh. Brick or stone veneer may be applied over theslabsV and wood ormetal siding of any desired type as well as wood orcomposition shingles may be employed as an external iinish. When woodsiding, shingles or panels of wood, metal or composite materials areemployed suitable nailing strips may be anchored to the slabs in anydesired Ulli manner such as. for example, by embedding or n anchoringbolts, metal clips or the like in the insulating material and attachingthe same to the nailing strips. Masonry veneer may also'be anchored tothe slabs in a similar manner.

It will also be understood that, although metal studs such as I-beams orH-columns are shown in theillustrations, wood framing may be employedwithcqual facility, in which case the wood studs may be of eithersquarerectangular, I or H Aof the invention, as defined by the appendedclaims. The same applies to various'modlcations and minor departuresfrom the specinc forms of wall slabs as well as the method and means ofattaching the wall slabs, herein illustrated and described.

I claim as my invention:

1. A wall comprising in combination spaced lstud members, slabs of wallmaterial disposed in pairs between said stud members, the outer faces ofwhich are disposed in substantially parallel planes, attaching meanscomprising hooks` carried by the side ends of said slabs and extendingfrom the body of the slabs, means carried by said studs for engagingwith said hooks whereby the inner faces of the slabs are carried by thestuds substantially flush with the outer portions of said studs, theouter portions of said studs and attaching means being covered by saidwall material.

2. A wall comprising in combination spaced stud members, slabs of wallmaterial disposed in pairs between said stud members, the outer faces ofwhich are disposed in substantially parallel planes, attaching meanscarried'by the side ends of said slabs and extending from the body ofthe slabs, hooks carried by said studs for engaging with said attachingmeans carried by the slabs whereby the inner faces of the slabs arecarried by the studs and lie substantially ush with the outer portionsof said studs, the outer portionsot said studs and attaching vmeansbeing covered by said wall material.

,3. A wall comprising in combination spaced stud members, slabs of wallmaterial the faces of which are disposed in substantially parallelplanes and extending between adjacent stud members, attaching meanscomprising auxiliary members secured to said slabs and studs at spacedintervals, certain of said auxiliary members being provided with slotsfor engaging other auxiliary members whereby to secure the slabs to thesaid studs, in a manner whereby the slab may be attached to thesupporting members by moving the slab in a plane at substantially rightangles to the face of the wall.

4. A wall comprising in combination spaced stud members, slabs of wallmaterial the faces of which are disposed in substantially parallelplanes and extending between adjacent stud members, attaching meanscomprising auxiliary members secured'to said slabs and studs at spacedintervals, certain of said auxiliary members comprising loops forengaging other auxiliary members whereby the slabs may be mounted uponstuds in adjacent relationship by moving the slabs in a planesubstantially at right angles to the face of the wall, whereby the innerfaces of the slabs lie fiat upon and are attached to the anges 'of thesaid studs.

5. A substantially vertical building wall comprising spaced supportingmembers carrying l panel supporting means, a wall panel of greater widthand length than thickness, said panel having substantially verticallyspaced recesses adjacent opposite side edges thereof said recessescontaining supporting means complementary to the supporting meanscarried by the supporting members, at least one of said supporting meanscomprising an open hooked member whereby the panel may be attached tothe supporting member by moving the panel in a plane at substantiallyright angles to the face of the wall.

y JACQUE C. MORRELL.

